Renu Electronics GWY-610 User manual

GWY-610
(Ethernet Gateway)
USER’S MANUAL

COPYRIGHT NOTICE
This manual is a publication of Renu Electronics Pvt. Ltd. and is provided for use by its customers only.
The contents of the manual are copyrighted by Renu Electronics Pvt. Ltd.; reproduction in whole or in part, for use
other than in support of Renu Electronics Pvt. Ltd. equipment, is prohibited without the specific written permission
of Renu Electronics Pvt. Ltd..
SERVICE
If service is required then pack the unit in its original packaging container or, if unavailable, any suitable rigid
container. If a substitute container is used, surround the unit with shock absorbing material; damage in shipment
is not covered by the warranty. Include a letter with the unit describing the difficulty and Hardware Revision and
Software Version. Send to the following address:
Renu Electronics Pvt. Ltd.
Survey No. 2/6,
Baner Road,
Pune-411045
India
All returns will be tested to verify customer claims of noncompliance with the product warranty. Improper return
packaging, which makes verification impossible, will void the warranty. If noncompliance is verified and is not due
to customer abuse or the other exceptions described with product warranty, Renu Electronics Pvt. Ltd. will, at its
option, repair or replace the Product returned to it, freight prepaid, which fail to comply with the foregoing
warranty, provided Renu Electronics Pvt. Ltd. is notified of such noncompliance within the one-year warranty
period.
ASSISTANCE
This manual is designed to provide the necessary information for trouble-free installation and operation of your new
Gateway product. However, if you need assistance, please call Renu Electronics Pvt. Ltd. at 91-20-27292840 or
visit our web site at www.renuelectronics.com
MANUAL REVISION
If you contact us in reference to this manual, please include the following document number
Name : Ethernet Gateway (GWY-610) User’s Manual
Part Number : URML207
Document : UMAN\GWY-610\1106
Revision : Revision 0
Revision Number Date Description
Revision 0 14/02/2007 First release

Warranty Certificate
For New product: This product is warranted against defects in materials and workmanship for a period of 12
months from the date of shipment to Buyer.
For Rectified Products:Any product that will be replaced will have Warranty for 6 months or upto Original Product
Warranty period whichever is greater.
The warranty is limited to repair or replacement of the defective unit at the option of the manufacturer. This war-
ranty is void if the product has been altered, misused, dismantled, or otherwise abused.
ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, ARE EXCLUDED, INCLUDING BUT NOT LIMITED TO
THE IMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR APARTICULAR PURPOSE.
MAINTENANCE & SERVICE :There are no parts that can be serviced by the user. Service should be performed
on a unit substitution basis only. Do not attempt to remove, replace or service any printed circuit board, compo-
nents or any hardware/software related with display product. If problem within the display product occurs, contact
the factory for service information or repair.
NOTE : Renu Electronics Pvt. Ltd. is dedicated to providing complete customer service and customer satisfaction.
If you have any comments or criticisms about how to improve the product features/reliability, Please make a note
of the problem/improvement and notify us. We are always open to new ideas and improvements. So please let us
know your ideas and comments.
IMPORTANT
Gateway Products are intended to be Protocol Converters/Data Sharer devices
that can also take control actions on request of device being connected. It is assumed that
user is well acquainted with the PLC / Inverters / Controllers being used.
Any Mechanical or Electrical Modification to this Unit will void
all Warranties.

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Contents
INTRODUCTION 1
1.1 Purpose of this manual 2
1.2 Introduction to Gateway 2
1.3 GWY-610 Specifications 3
HARDWARE 4
2.1 Dimensional details And Mounting Instructions 5
2.2 Communication Port Details 6
2.3 LED Status 7
GETTING STARTED 9
3.1 Introduction to GWY-610 10
3.2 GWY-610 Configuration 10
3.3 Configuration of GWY-610 (IBM Download) 10
3.3.1 When GWY-610 can accept configuration? 11
3.4 Quick Start To Ethernet 11
3.5 GWY-610 functionality and corresponding LED behaviour for different
phases of GWY-610 12
GWY-610 FEATURES 14
4.1 Gateway Modes 15
4.1.1 Master-Master Configuration 15
4.1.2 Master-Slave Configuration 17
4.2 Repeat Cycle 18
4.3 Control Word 19
4.4 Error Indication Bit 19
4.5 Communication Parameters 20
4.6 Default Communication Registers 20
4.7 Recipes 21
4.8 I/Os 22
NOTE ON COMMUNICATION DRIVERS 24
5.1 Note On Communication Drivers 25
5.1.1 How Modbus TCP server driver works? 25
5.1.2 How Modbus TCP Client driver works? 25
5.1.3 How other serial drivers work? 26
5.1.4 What is IDB (Internal Data Base)? 26
5.1.5 How does Pass Through work? 27
5.1.6 Control Word for IDB 28
TYPICAL PROJECTS 29
6.1 Project Setup 30
6.1.1 Connect Toshiba (link port protocol) PLC (e.g. T1, T2) as Modbus
TCP Server on Ethernet Network 31
6.1.2 Connect Toshiba (link port protocol) PLC (e.g. T1, T2) as Modbus
TCP Client on Ethernet Network: 34
CONFIGURATION SOFTWARE 38
7.1 System Requirements 39
7.2 Installation Instruction 39
CABLE DIAGRAMS 40
8.1 OMRON CQM/CPM CMOS PORT TO GWY-610 (EC-P-006A-00) 41
8.2 OMRON CQM1 PLC TO GWY-610 (EC-P-006B-00) 42
8.3 A B SLC DF1 PORT TO GWY-610 (EC-P-027B-00) 43

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8.4 TOSHIBA T1 LINK PORT TO GWY-610 (EC-P-046A-00) 44
8.5 TOSHIBA T1 PLC TO GWY-610 (EC-P-019A-00) 45
8.6 TOSHIBA T2 LINK PORT TO GWY-610 (EC-P-046B-00) 46
8.7 TOSHIBA T2 PLC TO GWY-610 (EC-P-019B-00) 47
8.8 TOSHIBA VF-S11 TO GWY-610 48
8.9 NS TO GWY-610 49
8.10 THOMSON TECHNOLOGY CONTROLLER TO GWY-610 (EC-P-117-00) 50
8.11 OPTOMUX TO GWY-610 51
8.12 ETHERNET CABLE 51
8.13 YOKOGAWA CONTROLLER TO GWY-610 52
8.14 IBM CABLE 53

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INTRODUCTION
In this chapter. . . .
♦Purpose of this manual
♦Introduction To Gateway
♦GWY-610 Specifications

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1.1 Purpose of this manual
Thank you for purchasing GWY-610 Product from Renu Electronics Pvt. Ltd..
The intention of this User Manual is to provide a guide for Safe installation, Configuration and operation of GWY-
610-B or GWY-610-G.
Functionality of all the Gateway models is same. Read this User manual thoroughly before installing and
operating GWY-610. This document is based on information available at the time of its publication. While efforts
have been made to be accurate, the information in this document may not cover all the details or variations in
hardware or software. Features described herein may not be present in all hardwares. Renu Electronics Pvt. Ltd.
reserves the right to update information in this publication without prior notice.
1.2 Introduction to Gateway
Gateway is a Protocol Converter / Data sharer for devices like PLCs, inverters (Adjustable Speed Drives), and
other Controllers. Gateway has two serial ports that connect with two different devices. These devices share data
through Gateway. Gateway communicates with a device to get the information required by the device connected on
the other port. The device that requires data is called Destination Device and the device that provides data is called
Source Device. Information could be,
- value of a PLC register.
- status of a PLC coil.
- Command from Source Device to Destination Device to perform any action at the destination end.
Configuration Of Gateway
Note: Please refer ‘IBM Download’ in section 3.4.
Normal Operation:
Connect Modbus TCP devices to Gateway via Ethernet port and serial device (PLC or Inverter) via PLC’s commu-
nication port (correct cables are required) and PLCs can easily exchange information through Ethernet. At the
same time local HMI can communicate with PLC connected on serial port.
HMI
Modbus TCP Client / Server
Pass Through Port
Serial Port
PLC 1

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1.3 GWY-610 Specifications
Power : 24 V DC, 2.5 W
LED’s : 16 LED’s for status indication
Communication Ports : 3 Communication ports with
COM1 : RS232 / RS422 / RS485 / CMOS
COM2 : ETHERNET
COM3 : RS232
(Isolation between communication ports and Power supply, through DC-DC coupler is 1 KV)
COM1 / PLC1 : Connects to PC for setup download or connects to PLC1 at
runtime.
COM2 / PLC2 : ***Connects to PLC2 at runtime
COM3 (Pass Through for COM1): *SCADA or local HMI can be connected
(Isolation between COM 1 and COM2 communication ports, through Opto-isolation is 1KV rms for 1 min
Isolation between COM 3 and COM2 communication ports, through Opto-isolation is 1KV rms for 1 min)
**Digital Inputs : 0 to 5 V DC low
12 to 28 V DC high
**Digital Outputs : Relay Outputs
230VAC; 2Amp/30VDC; 2Amps
Coil voltage 24VDC
**I/O Terminals : Pluggable Terminals
Ethernet Baud Rate : 10/100 Mbps (Autodetect)
OperatingTemperature : 0oto 60oC
Storage Temperature : -20oto 80oC
Humidity : 10% to 90% (Non condensing)
Mounting : DIN rail or back panel mounting
Dimensions (DIN rail) : 100mm(L) X 35mm(D) X 70mm(W)
Weight : 200 gm approx.
Certifications : CE with UL certification
Immunity to ESD : Level 3 as per IEC1000-4-2
Immunity to Transients : Level 3 as per IEC1000-4-4
Immunity to Radiated RF : Level 3 as per IEC1000-4-3
Immunity to Conducted RF : Level 3 as per IEC1000-4-6
Emissions : EN55011 CISPRA
*Note: For more details on pass through, please refer section, Note on communication drivers
**Note: Not all models support digital I/Os.
***Note: ARP, RARP, IP, TCP, UDP Protocols are supported.
At application layer Modbus TCP server and Modbus TCP clients are supported at present.
New protocols based on tcp and udp are constantly added (e.g. ethernet ip). Contact factory for more
information.

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HARDWARE
In this chapter. . . .
♦Dimensional DetailsAnd Mounting Instructions
♦Communication Port Details
♦LED Status

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2.1 Dimensional details And Mounting Instructions
GWY-610-B unit can be shipped with a separate DIN rail plate which can be attached to the unit, if desired. User
can use the unit with or without the DIN rail plate. Following sketch shows dimensional details of Gateway with the
DIN rail plate.
Follow instructions given below:
1.Attach the DIN rail plate to the unit using the clamps on the DIN rail plate.
2. Pull out the clip of the plate.
3. Put the unit on the DIN rail.
4. Push the clip in to secure the unit on the DIN rail.
70.00
100.00
35.00

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2.2 Communication Port Details
GWY-610 has three communication ports COM1, Ethernet and Pass Through Port. COM1 port is compatible to
RS232/ RS422/ RS485 and CMOS signal levels. Pinout of this port is given as follows:
TX-(RS422/RS485)
DB9 Female
1
5
9
6
+5VDC*
(DO NOT USE)
SignalGround
RX+(RS422/RS485)
RXD(RS232C/CMOS)
TXD (RS232C)
TX+(RS422/RS485)
TXD(CMOS)
RX-(RS422/RS485)
6
8
9
72
4
5
3
1
PLC1 / COM1
*Do not use pin no. 6 of PLC1 / COM1.
**Refer our website (www.renuelectronics.com) for your specific Cable requirements
Ethernet Port:
Pin Signal
1 Twisted Pair Transmit Output (Positive)
2 Twisted Pair Transmit Output (Negative)
3NC
4NC
5NC
6NC
7 Twisted Pair Receive Input (Positive)
8 Twisted Pair Receive Input (Negative)
Pass Through Port:
Pin Signal
1 TXD
2 RXD
3SG
4NC
5NC
6NC
7NC
8NC
COM1 (RS232/RS485/CMOS) ETHERNET PASS THROUGH
(RS232)
OK COM1 ETHERNET PASS
THROUGH
GWY-610-B
24V
DC+
24V
DC-
Pin1 Pin1

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2.3 LED Status
There are 13 LEDs for status indication.
LED
OK Green OFF No Firmware
Flashing *IBMDownload
ON Communication OK
Red OFF Configuration Ok
ON Configuration Fault
COM1 Green OFF No data received on COM1 Port
Flashing Receiving data on COM1 Port
ON -
Red OFF No error in COM1 attach or while block execution
Flashing -
ON PLC1 attach error or error while block execution
ETHERNET Green OFF Connection is not open with server
ON Connection is open with server
Red OFF No IP conflict
ON IP conflict or ModbusTCP server not attached
Pass Through Green OFF No data received on Pass Through Port
Flashing Receiving data on Pass Through Port
ON -
X0 Green OFF Digital input 0 is ON
ON Digital input 0 is OFF
X1 Green OFF Digital input 1 is ON
ON Digital input 1 is OFF
X2 Green OFF Digital input 2 is ON
ON Digital input 2 is OFF
X3 Green OFF Digital input 3 is ON
ON Digital input 3 is OFF
Y0 Green OFF Digital output 0 is ON
ON Digital output 0 is OFF
Y1 Green OFF Digital output 1 is ON
ON Digital output 1 is OFF
Table continued on next page....

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Y2 Green OFF Digital output 2 is ON
ON Digital output 2 is OFF
Y3 Green OFF Digital output 3 is ON
ON Digital output 3 is OFF
*Note: For more information, please refer section 3.3.1.
For more information on LED behaviour, refer section 3.5.1
Not all models support I/Os and respective LED’s

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GETTING STARTED
In this chapter. . . .
♦Introduction To GWY-610
♦GWY-610 Operation
♦Quick Start To Ethernet
♦GWY-610 Function

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3.1 Introduction to GWY-610
GWY-610 is a communication bridge between Ethernet interface on one side and various serial protocols on the
other side. GWY-610 allows serial devices to act as Modbus TCP Client or Modbus TCP slave on Ethernet.
On COM1 side it supports serial protocols (e.g. Modbus Master, Modbus Slave) and on COM2 side it has Modbus
TCP Client and Modbus TCP Server.
COM3 port acts as pass through for COM1*.
GWY-610 is externally powered from 3 pin terminal block and power is isolated from communication ports. Both
the communication ports are also isolated from each other.
It has three communication ports, one with Ethernet interface (10/100 Mbps) and one serial port with RS232 /
RS422 / 2 or 4 wire RS485 (300 to 115.2K), second serial port with RS232 (300 to 115.2K)
*Note: For more details on pass through …please refer to section 5.1.5
3.2 GWY-610 Configuration
GWY-610 can communicate with serial and Ethernet devices using appropriate cables and configuration.
Microsoft Windows® based configuration software, Gateway Setup, configures the GWY-610 unit.
‘Configuration’ means making the GWY-610 unit work as per system requirements.
Complete configuration for a GWY-610 using the Gateway Setup is termed as a ‘Project’. A Project consists of
Devices to be attached on two ports, Communication settings for two ports to communicate with two devices,
Register addresses for data transfer, Conditions for data transfer etc.
GWY-610 can now communicate with the specified devices without any change in the GWY-610 hardware. To
communicate with a device, GWY-610 needs Communication Drivers for the devices and ‘Gateway - Device’
communication cables.
Each Device has a unique and predefined protocol for communication. GWY-610 driver has this protocol to
communicate with the desired device.As two devices are connected on GWY-610, it requires two drivers for
communication
3.3 Configuration of GWY-610 (IBM Download)
User MUST download Firmware, Project, PLC1 driver and PLC2 driver in Gateway before installing any system-
usingGateway.
User needs a special IBM download cable for downloading configuration in Gateway.All configurations can be
downloaded only form Serial port (Port 1).
If any change in the current / working project is made, user must download the changed project in Gateway
DB9 Male (Gateway) DB9 Female (IBM)
22
33
55
1. For downloading Firmware,drivers and project switch off the GWY-610 unit.
2. Power ON the unit again.Ok LED starts blinking.This means that unit is in download mode.
3. For the first time download all firmware, drivers and project.
IMPORTANT NOTE:
AS GATEWAY HAS MULTIPLE SIGNALS ON ITS COMMUNICATION PORTS, IBM CABLE FOR GATEWAY
MUST HAVE ONLY THREE RS232 SIGNALS (TXD, RXD AND GND) AS MENTIONED ABOVE.
9-9 PIN CORE CABLE SHOULD NOT BE USED.
If you are using USB to serial converter then please connect IBM cable to serial port of converter

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3.3.1 When GWY-610 can accept configuration?
If current driver present for PLC1 port is Master (e.g. Modbus (Gateway as master))
First, it is checked that whether device is connected on port1
If device is connected, it continues normal operation
If device is not connected, it checks for IBM download mode for 10sec.
This sequence continues until either is satisfied.
If current driver present for PLC1 port is Slave (e.g. Modbus (Gateway as Slave))
If Port1 of Gateway is Slave, all the configurations should be downloaded Only once for 10sec at power on.
Note: Make sure that OK LED is blinking when you start downloading the configuration in Gateway.
3.4 Quick Start To Ethernet
This section provides quick example on how to get Ethernet running
GWY-610 supports Modbus TCP Client as well as Modbus TCP Server at present.
These settings are for GWY-610
STEP 1 Configure the GWY-610 IP address
User should configure IP address for GWY-610 through Gateway setup software.
PLC2 Settings->Advanced->Extended Setup->IP address
STEP 2 Configure Subnet Mask
User should configure Subnet Mask for GWY-610 through Gateway setup software.
PLC2 Settings->Advanced->Extended Setup->Subnet Mask
Please note that gwy-610 IP address should be unique
STEP 3 Configure Default GatewayAddress
User should configure Subnet Mask for GWY-610 through Gateway setup software.
PLC2Settings->Advanced->ExtendedSetup->GatewayAddress
In case of Modbus TCP Client, some settings additional to above three are required and are as given below:
These settings are for PLCs with which GWY-610 will communicate.
STEP 4 Configure Node address
Node address should be configured through Source address / Destination address through data
exchange blocks
STEP5 Configure NodeAddress, IPAddress, Port Number
User should configure Node Address, IPAddress, Port Number for PLCs with which GWY-610 will communicate,
through Gateway Configuration Software
Settings->Ethernet node table
Note : User can get the Information required for STEP 2 and STEP 3 through PC as follows
(1) Make sure , the PC is connected in Network through Ethernet cable.
(2) Go to command Prompt on PC

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(3) Type ipconfig/all
Note :
After the entire configuration is downloaded in GWY-610. And after power on when OK LED is steady, user can
ping the unit with GWY-610’s IP address. If the response is received to the ping command, it means all Ethernet
configuration is correct.
C:\>ping <IP address of GWY-610>
3.5 GWY-610 functionality and corresponding LED behaviour for different phases of GWY-
610
The GWY-610 initialization can be divided into three stages:
1) EthernetInitialization Phase
Here baud rate is determined by auto negotiation and IP conflict is checked.
2) SerialInitializationphase
Here the communication parameters are initialized.
And it’s checked whether the external slave is connected on the port.
3) Ethernet attach phase
Here it’s checked whether the external server is connected on the port.
The above-mentioned phases are executed sequentially.
‘EthernetInitialization phase’:
At power on, GWY-610 initializes the Ethernet port. Here the OK LED flashes at faster (relative to the IBM Down-
load mode) rate. While initialization it checks for IP conflict.
If IP conflict occurs; ETHERNET RED LED is lit for a second and then it enters to configuration (download) mode
for 10 seconds.After 10 seconds it again checks for any IP conflicts. This cycle is repeated till the valid configura-
tion with valid IP address is downloaded.
If there is no IP conflict; GWY-610 enters the “Serial Init phase”.
Serial Init phase:
Here the GWY-610 starts scanning nodes that are connected on COM1 port. OK LED is lit green at this time.
If GWY-610 does not get response from COM1 port, it enters in configuration (download) mode.
The OK LED flashes green at this stage. It remains in configuration mode for nearly 10 seconds. The configuration
mode is used for firmware, drivers and project download / upgrade.
After 10 seconds, it again starts scanning for the node. This cycle continues until GWY-610 gets the response from
COM1. Other LEDs will remain off till the cycle is repeating.
After getting response from COM1 port, GWY-610 starts communication on the COMM1 port.
COM1 LED flashes green at this stage and OK LED is steady green.
Now the GW-610 enters the “EthernetAttach Phase”.
EthernetAttach Phase:
It starts attaching to Ethernet nodes. Then according to Modbus TCP
Client or Modbus TCPServer driver present in Gateway following is done
(a) In case of Modbus TCP server driver, GWY-610 waits for request from external client.
(b) In case of Modbus TCP client driver, GWY-610 sends request to open connection to external server/s and
wait for the response. If connection is opened successfully; ETHERNET LED will lit green. Otherwise it
Continuously try to open the connection to external server.

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GWY-610 FEATURES
In this chapter. . . .
♦GatewayModes
♦RepeatCycle
♦Control Word
♦Error Indication Bits
♦Communication Parameters
♦Default Communication Registers
♦Recepies
♦I/Os

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4.1 Gateway Modes
Gateway has two modes of operation: Master-Master and Master-Slave. Before explaining these modes further
Master and Slave concept should be explained.
Master:
Master is a Device / device driver which initiates communication.
Slave:
Slave is Device / Device driver which processes Master’s query, takes necessary action and responds to the query,
if necessary.
4.1.1 Master-Master Configuration
In this mode both Gateway ports are master in nature and devices connected on these ports are slave. Gateway
ports initiate communication when the proper Gateway-Device communication cable is attached. Data is
transferred in blocks.
This transfer can either be a continuous process or as per requirement.A control word , present in device on
either side, enabled from Gateway Setup Software, can control the block execution.
When control word is disabled, then block transfer is a continuous process. Ablock of data is fetched from one
device and transferred to the other device. The amount of data to be transferred (Number of words) depends on
Block definition in “Block DefinitionArea” in Configuration Software. One block is executed at a time.Acycle
consists of execution of blocks from #1 to #n.
Execution of blocks is performed as follows:
Block #1
Block #2
Block #3
Block #4
Block #n
.
.
.
.
.
When Control word is enabled, it decides which block has to be executed by writing a specific data in the control
word.